Microwave browning composition and process for producing the same

ABSTRACT

Described is a process for producing a cooked edibly browned storage-stable fibrous proteinaceous muscle tissue foodstuff including the steps of: 
     (a) providing a particulate flowable flavoring powder which contains individually discretly encapsulated Maillard reaction reagents with the reaction reagents being at least one enxapsulated amino acid and at least one encapsulated sugar; 
     (b) providing an uncooked fibrous proteinaceous muscle tissue foodstuff containing more than 50% water; 
     (c) placing in intimate the contact with at least part of the surface of the foodstuff, a flavor augmenting, imparting or enhancing quantity of the particulate flowable flavoring powder of (a); and 
     (d) exposing the flavoring powder coated foodstuff surface to microwave powder-radiation for a period of time to cause the foodstuff to be edible 
     whereby the resulting product is caused to be edible as a foodstuff and the cooked fibrous proteinaceous muscle tissue is edibly browned. Optionally, the particulate flowable flavoring powder may be in the form of a slurry with a solvent composition which is capable of raising the dielectric constant of the foodstuff to be cooked whereby the foodstuff to be cooked is completely cooked and edibly browned in the period of time under 600 seconds.

This is a division of application Ser. No. 535,524, filed 6/8/90, nowU.S. Pat. No. 4,985,261, which is a continuation-in-part of applicationSer. No. 440,794, filed on 11/24/89, now U.S. Pat. No. 4,943,697, issued7/24/90, which is a division of application Ser. No. 356,503, filed on5/25/89, now U.S. Pat. No. 4,904,490, issued 2/27/90, which is acontinuation-in-part of application Ser. No. 295,450, filed on 1/10/89,now U.S. Pat. No. 4,882,184, issued 11/21/89.

BACKGROUND OF THE INVENTION

The increased use of microwaves for cooking has given rise to a largemarket in microwavable foods. While the advantage of microwave cookingover convection oven cooking is the time savings, the disadvantage isthat proteinaceous fibrous muscle tissue (e.g. turkey meat, chickenbreast, brisket of beef, swordfish steak and the like) do not developthe surface browning or crust formation expected with convection ovencooking.

Our objective has been to create that browning which enhances theproducts appearance, making it look as if it were cooked in a convectionoven.

In the microwave, food does not have sufficient time or temperature forthe chemicals responsible for browning to react. Therefore, for amicrowave browning system to work, it must accelerate the rate of thebrowning reactions or locally increase the surface temperature.Ultimately, the reactions responsible for browning have to beaccomplished in the relatively short time frame dictated by the foodspreparation conditions. The times needed for preparing microwave foodsvary depending upon the power output of the microwave unit and the massof the food to be cooked and the nature of the food to be cooked. Atypical 750 watt microwave will cook proteinaceous fibrous muscle tissuefoodstuffs in 6 to 15 minutes.

Several additional requirements for a successful microwave browningsystem are as follows:

1. In addition to the desired browning effect, it must generate eitherno aroma or one which is compatible with the target foodstuff;

2. The browning reaction must not take place before cooking thefoodstuff;

3. After cooking, the browning must stop, and not darken the foodstuffsubstantially.

The reactions responsible for browning during convection oven cookingare the caramelization of sugars and the Maillard reaction betweennaturally occurring reducing sugars, amino acids, amines, peptides andproteins which results in the formation of colored melanoidins. Untilrecently (1984) there were numerous patent and literature references tosuch reactions for the production of flavors, where the generation ofcolor was inconsequential or objectionable. In the past few yearsseveral patents have appeared wherein microwave browning created byMaillard reactions have been the topic. Thus, Bryson, et al. in U.S.Pat. No. 4,735,812 issued on Apr. 5, 1988 discloses a browning agentparticularly for use in microwave cooking comprising collagen or gelatinhydrolyzed to its constituent amino acids plus one or more reducingsugars and alkalis. It is further indicated in Bryson, et al. that thecollagen preferably is derived from Bovine hides, and that the alkalisare preferably a mixture of sodium carbonate and bicarbonate. It isfurther indicated that the browning agent may be incorporated into afilm or used as a powder or liquid.

Parliment et al. U.S. Pat. No. 4,857,340 issued on Aug. 15, 1989discloses a composition of an aroma producing material enrobed in afusible encapsulating agent, preferably a lipid and in conductive heattransfer relationship with a microwave susceptible material whencombined with a microwave comestible or package for providing an aromawhen the comestible or package is prepared by subjecting the comestibleor package and composition to microwave energy.

Kim et al., "Formation of Volatile Compounds from Maillard Reaction ofD-Glucose with DL-Alanine in Propylene Glycol Solution", Han'guk Sikp'umKwahakhoechi 1988, 20(2), 157-63 (Korea), (Abstracted at ChemicalAbstracts Volume 112 at 34512q) discloses volatile compounds producedfrom the browning reaction of alanine and glucose using propylene glycolas a reaction medium.

Although the prior art does take advantage of the reaction betweenreducing sugars and amino acids, it has not made any correlation ofreaction rates needed for browning reactions with reaction variablessuch as pH solvent, or sugar reactivity in connection with browningreactions concerning the surface of proteinaceous muscle tissue such aschicken breast.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cut-away side elevation view of a slurry-coated food articlesection coated with a fluid having intimately admixed therewithencapsulated Maillard reaction reactants (with optional pH adjustmentagent) prior to carrying out the microwave browning step of the processof our invention.

FIG. 1A is a cut-away side elevation view of an encapsulated Maillardreaction reactant, namely sugar encapsulated in fat.

FIG. 1B is cut-away side elevation view of an encapsulated Maillardreaction reagent, namely sodium carbonate encapsulated in fat.

FIG. 1C is a cut-away side elevation view of an encapsulated Maillardreaction reactant, namely an amino acid encapsulated in fat.

FIG. 1D is a cut-away side elevation view of a poultry drumstick coatedwith fluid containing encapsulated Maillard reaction product reactants.

FIG. 2 is a cut-away side elevation view (in schematic form) of amicrowave oven containing a coated food article (coated with fluidcontaining encapsulated Maillard reaction product reactants) prior toand during the carrying out of the process of our invention.

FIG. 2A is a cut-away side elevation view (in schematic form) of amicrowave oven containing a coated food article (coated withencapsulated Maillard reaction product reactants) prior to and duringthe carrying out of another embodiment of the process of our invention.

FIG. 2B is a cut-away side elevation view of a coated food articlesection coated with encapsulated Maillard reaction product reactants(with optional pH adjustment agent).

FIG. 3 is a block flow diagram showing the steps, in schematic form forcarrying out the process for forming drum chilled Maillard reactionproduct reactant in encapsulated form and spray chilled Maillardreaction product reactant in encapsulated form useful in the practice ofthe process of our invention.

FIG. 4 is a schematic diagram setting forth apparatus and process stepsuseful in forming spray chilled Maillard reaction product reactantflavor precursor (in encapsulated form) useful in the practice of theprocess of our invention.

FIG. 5 is a flow diagram setting forth in schematic form the apparatusand process steps required in producing drum chilled Maillard reactionproduct reagents in encapsulated form useful in the practice of theprocess of our invention.

FIG. 6 is a block flow diagram showing the steps, in schematic form, forcarrying out the process of our invention and indicating the multiplemeans (apparatus elements) useful in carrying out the process of ourinvention whereby an uncooked proteinaceous muscle tissue food articleis coated with encapsulated Maillard reaction product reagents,individually, in slurry form, prior to microwave heating.

FIG. 7 is a block flow diagram showing the steps, in schematic form, forcarrying out another aspect of the process of our invention andindicating the multiple means (apparatus elements) useful in carryingout that aspect of the process of our invention wherein browningprecursor powder (encapsulated Maillard reaction product reagents) isapplied to a portion of the surface of the uncooked food article priorto microwave heating.

SUMMARY OF THE INVENTION

Our invention is directed to a process for producing a cooked ediblybrowned storage stable fibrous proteinaceous muscle tissue foodstuffcomprising the steps of:

(a) providing a particulate flowable flavoring powder consistingessentially of @ individually discretly encapsulated Maillard reactionreagents, which Maillard reaction reagents are:

(i) at least one encapsulated amino acid;

(ii) at least one encapsulated sugar optionally admixed with at leastone Maillard reaction promoter, and optionally

(iii) at least one encapsulated pH adjustment agent and, optionally β atleast one Maillard reaction promoter;

(b) providing an uncooked fibrous proteinaceous muscle tissue foodstuffcontaining more than 50% of water having an outer uncooked foodstuffsurface;

(c) placing in intimate contact with at least a major portion of saiduncooked foodstuff surface a flavor augmenting, imparting or enhancingquantity of said particulate flowable flavoring powder thereby forming aflavoring powder-coated foodstuff surface; and

(d) exposing the flavoring powder-coated foodstuff surface to microwaveradiation for a predetermined controlled period of time,

whereby the resulting product is caused to be edible as a foodstuff andthe cooked fibrous proteinaceous muscle tissue foodstuff surface isedibly browned.

Our invention is also directed to the optional embodiment ofincorporating the particulate flowable flavoring powder in admixturewith a liquid whereby a slurry is formed with a solvent compositionwhich is capable of raising the dielectric constant of the proteinaceousmuscle tissue foodstuff to be cooked whereby the foodstuff to be cookedis completely cooked and edibly browned in a period of time under 600seconds.

Our invention is also intended to encompass a process wherein theparticulate flowable flavoring powder is prepared according to a processcomprising the steps of:

(i) heating a high melting point normally solid encapsulating materialto melt the encapsulating material forming a molten encapsulating agent;

(ii) separately mixing each of the Maillard reaction reagent containingcomponents of the Maillard reaction reagent containing composition withdiscrete individual portions of the molten encapsulating agent; and

(iii) spray chilling or drum chilling the Maillard reaction reagentcontaining composition mixture to provide discrete particles of solidMaillard reaction reagent-containing agent.

Our invention is also directed to another embodiment of theaforementioned process wherein the particulate flowable flavoring powderis prepared according to a process comprising:

(i) heating a high melting point normally solid encapsulated materialand at least one emulsifier to melt the encapsulating material andemulsifier;

(ii) admixing the melted encapsulating material and emulsifier;

(iii) separately mixing each component of the Maillard reaction reagentcontaining composition with a textured conditioning agent;

(iv) separately mixing each component of the Maillard reaction reagentcontaining composition and textured conditioning agent with discreteindividual portions of the molten mixture of encapsulating agent andemulsifier to obtain homogeneous mixtures in the form of emulsions;

(v) mixing the resulting emulsions; and

(vi) chilling the resulting Maillard reaction reagent containingcomposition-containing mixture to provide discrete particles of solidencapsulated Maillard reaction reagent containing composition.

Our invention is also directed to the products produced according tosuch process.

With reference to that aspect of our invention involving the utilizationof particulate flowable flavoring powder in the form of a slurry with asolvent composition which is capable of raising the dielectric constantof the foodstuff to be cooked, whereby the foodstuff to be cooked iscompletely cooked and edibly browned in a period of time under 600seconds a mathematical model useful in relating each of the variablesinvolved in the development of our invention is set forth thusly:##EQU1##

In an approximate version an equation for calculating the time ofheating as a function of viscosity of the coating (prior to cooking) andfurther, as a function of the temperature differential between thecenter of the food article to be cooked and the outer surface of thecoating during the microwave browning operation is set forth thusly:##EQU2## wherein the terms

    ΔQ

is the total microwave energy input during the process of our invention;##EQU3## is the rate of heat input equivalent to the rate of energy useby the microwave oven;

    R

is the effective radius of the food article being cooked;

    K

is the heat transfer coefficient of the food article being cooked (thesolid material);

    μ

is the viscosity of the coating immediately prior to cooking;

    λ.sub.1

is a proportionality constant which is a function of the coatingthickness immediately prior to cooking and the geometry of the articlebeing cooked as well as the geometry of the microwave oven;

    C.sub.p

is the heat capacity of the coating immediately prior to cooking;

    ρ

is the density of the liquid coating immediately prior to cooking;

    T.sub.1

is the temperature at the center of the food article being cooked;

    T.sub.2

is the temperature at the outer surface of the food article beingcooked;

    h.sub.r

is the convection heat transfer coefficient for the air layersurrounding the food article being cooked;

    λ.sub.2

is the proportionality constant for radiation term for concentricspheres (the coating surrounding the uncooked food);

    ε

is the electric field strength;

    ν

is the frequency;

    ε'

is the relative dielectric constant of coating material; and

    Δθ

is the time of the microwave cooking.

The foregoing equations were derived from equations set forth in:

"Heat Transfer and Food Products", Hallstrom, et al, Elsevier AppliedScience Publishing Company, 1988;

"Principals of Chemical Engineering", Walker, et al, Third Edition,McGraw Hill Book Company, 1937; and

"Chemical Engineer's Handbook", Fifth Edition, Perry and Chilton, McGrawHill Book Company, pages 10-10, 10-11 and 10-12.

Our invention is also intended to cover apparatus for carrying out theaforementioned process which apparatus consists essentially of:

(i) separate encapsulating means for encapsulating Maillard reactionreagents to produce separate batches of capsules each containing anindividual Maillard reaction reagent;

(ii) mixing means for mixing the separate batches of capsules to form asingle batch of flowable capsules;

(iii) coating means for coating the said batch of capsules preparedusing said mixing means onto an uncooked fibrous proteinaceous muscletissue foodstuff, said coating means being downstream from said mixingmeans; and

(iv) microwave cooking means downstream from said coating means to cookthe coated uncooked fibrous proteinaceous muscle tissue foodstuff,whereby it becomes cooked, edibly browned and storage stable.

Another embodiment of the apparatus of our invention consistsessentially of:

(i) separate encapsulating means for encapsulating Maillard reactionreagents to produce separate batches of capsules, each capsule includingan individual Maillard reaction reagent;

(ii) first mixing means for mixing the separate batches of capsules toform a single batch of flowable capsules;

(iii) second mixing means downstream from said first mixing means formixing said batch of flowable capsules with a solvent composition whichis capable of raising the dielectric constant of a foodstuff to becooked, whereby the foodstuff to be cooked is completely cooked andedibly browned in a period of time under 600 seconds, said second mixingmeans capable of handling a slurry consisting of said solvent and saidflowable capsule;

(iv) coating means for coating the slurry prepared in using said secondmixing means onto uncooked fibrous proteinaceous muscle tissuefoodstuffs; and

(v) microwave cooking means downstream from said coating means to cookthe coated uncooked fibrous proteinaceous muscle tissue foodstuff or bysaid foodstuff becomes cooked, edibly browned and storage stable.

Preferred encapsulating materials have melting points of from about 130°F. up to about 195° F. and are more preferably fats or waxes having suchmelting points. Desirably, the encapsulating material is a hydrogenatedor partially hydrogenated vegetable oil, stearate, a fatty glycerideester or partial ester or a edible wax. More particularly theencapsulating agent is preferably a partially hydrogenated cottonseedoil, a partially hydrogenated soybean oil, a partially hydrogenated palmoil, a glycol monostearate, a glycerol monopalmitate, a propylene glycolmonostearate, a polyglycerol stearate, a polyoxyethylene sorbitol, afatty acid ester of polyoxyethylene sorbitan, a polyglycerol ester offatty acid, bees wax, carnauba wax, paraffin wax or candellila wax.

When a texture conditioning agent is used, it is preferred that thequantity of textured conditioning agent is from about 0.1 up to about 1times the amount of Maillard reaction reagent containing compositionused.

When the encapsulation process is spray chilling, it is preferred thatthe homogeneous mixtures chilled by spraying the mixture into a streamof gas with the gas being preferred to have a temperature of from about40° F. up to about 116° F. It is further preferred that the spraying becarried out using a centrifugal atomizer. It is further preferred thatthe homogeneous mixture be admixed with compressed air and sprayedthrough a nozzle. Furthermore, the mixture may be chilled by contactwith a surface at a temperature less than the melting point of theencapsulating material to form flakes; and it is preferred that theflakes are reduced in size to pass through a number 10 screen prior tofurther use.

When using a solvent to form a slurry of capsules, the solvent ispreferred to be glycerine, propylene glycol, mixtures of glycerine andpropylene glycol from one part glycerine up to 99 parts propylene glycoldown to 99 parts glycerine to 1 part propylene glycol, mixtures ofglycerine and ethanol wherein the ethanol:glycerine ratio is from 50parts ethanol:50 parts glycerine down to 1 part ethanol:99 partsglycerine and mixtures of propylene glycol and ethanol wherein the ratioof propylene glycol:ethanol is from 50 parts propylene glycol:50 partsethanol down to 99 parts propylene glycol:1 part ethanol.

It is preferred that the sugar reactant in the Maillard reaction productreagent composition is one of the following sugars:

Rhamnose;

Xylose;

Arabanose;

Ribose;

Fructose; and

Glucose

Furthermore, it is preferred that the amino acid reactant in theMaillard reaction reagent composition is one of the following aminoacids:

Lysine;

Arginine;

Cysteine

Methionine;

Yeast Extract; and

Hydrolyzed Vegetable Protein.

It is also preferred that the Maillard reaction reagent particles bereduced in size to pass through a 100 mesh screen prior to their beingencapsulated.

A Maillard reaction promoter such as polyvinyl pyrrolidone, may,optionally be encapsulated along with the sugar prior to being placed onthe surface of the proteinaceous muscle tissue prior to microwavecooking.

Furthermore, the Maillard reaction promoter such as polyvinylpyrrolidone may be separately added to the encapsulated Maillardreaction reagent composition prior to coating on the proteinaceous meatmuscle tissue prior to microwave cooking.

In one aspect of our invention each of the browning precursors (Maillardreaction product reagents) are individually incorporated into acontrolled release system prior to coating onto the proteinaceous muscletissue foodstuff to be cooked via microwave cooking. Thus, for example,the amino acid precursor or mixture of amino acid precursors are admixedwith a fat in a weight ratio from 1 part amino acid precursor to 2 partsfat down to 1 part fat composition to 2 parts precursor composition. Theresulting mixture is drum chilled as more specifically set forth in theexamples infra. The drum chilled product is then admixed with asimilarly formed drum chilled or spray chilled encapsulated sugar andsimilarly formed drum chilled or spray chilled encapsulated sodiumcarbonate. The resulting mixture is then either admixed with a solventas set forth supra or per se coated onto a meat product, for example:

Turkey meat;

Chicken breast;

Brisket of Beef;

Swordfish Steak; and

the like.

The resulting product is then placed in a microwave oven and themicrowave oven is maintained in heating mode for a period of at least 6minutes. The resulting product is edibly browned and has substantiallyentire flavor retention.

DETAILED DECRIPTION OF THE DRAWINGS

Referring to the drawings, FIG. 1 is a cut-away side elevation view of aslurry-coated food article section 12 coated with a fluid such asglycerine 10 having intimately admixed therewith encapsulated Maillardreaction reactants with optional pH adjustment agent prior to carryingout the microwave browning step of the process of our invention.

Thus, the solvent composition 10 is capable of raising the dielectricconstant of the foodstuff 12 to be cooked whereby the foodstuff 12 to becooked is completely cooked and edibly browned in a period of time offrom 6 to 15 minutes (under 900 seconds and preferably under 600seconds). The solid components of the slurry have been previouslyencapsulated according to the processes as set forth in FIGS. 3, 4 and5. More specifically, the particle indicated by reference numeral 16 isa fat encapsulated sugar particle with the fat being indicated byreference numeral 28 and the sugar being indicated by reference numeral30. This particular particle is also shown in detailed cross-sectionform in FIG. 1A. Furthermore, the particle indicated by referencenumeral 18 is a fat encapsulated sodium carbonate particle with the fatindicated by reference numeral 26 and the sodium carbonate indicated byreference numeral 32. The sodium carbonate is a pH adjustment agent forthe Maillard reaction which is carried out during the microwave heating.Similarly, the particle indicated by reference numeral 20 is a fatencapsulated amino acid particle with the amino acid itself beingindicated by reference numeral 34 and the fat encapsulating the aminoacid being indicated by reference numeral 24.

FIG. 1D is a poultry drumstick coated with fluid (indicated by referencenumeral 10) containing encapsulated Maillard reaction reagent reactants.The particles set forth in FIGS. 1A, 1B and 1C are once again repeatedusing the same reference numerals in FIGS. 1D. Thus, reference numeral10 indicates the solvent such as glycerine or a mixture of propylenegylcol glycerine. Reference numeral 16 indicates the encapsulated sugar.Reference numeral 18 indicates the encapsulated sodium carbonate.Reference numeral 20 indicates the encapsulated amino acid. Referencenumeral 12 indicates the proteinaceous meat on which the slurry iscoated, in this case being the meat of a turkey drumstick or a chickendrumstick. The same drumstick is set forth in schematic form in FIG. 2.

Thus, FIG. 2 is a cut-away side elevation view (in schematic form) of amicrowave oven indicated by reference numeral 138 containing a coatedfood article of the type set forth in cross-section form in FIG. 1-D.The food article having the slurry coating on the uncooked proteinaceousfoodstuff 12 is contained in microwave oven 138, more specifically inbox 40 wherein microwave source 42 emits energy substantiallyperpendicular to the upper surface of the food article. The microwaveenergy passes through the coating surface and causes the reaction in thecoating which contains solvent 10 and encapsulated Maillard reactionreagent reactants 34 and 30 to take place whereby Maillard reactionproducts are produced. The solvent 10 heats up and activates themolecules of the reactants. Simultaneously, the solid proteinaceousfibrous meat material 12 is heated and the coating containing thesolvent 10 is adsorbed through the surface of the proteinaceousfoodstuff into the outer interstices of the proteinaceous meat 12. Priorto 900 seconds (preferably 600 seconds) the entire proteinaceous fibrousmeat product is cooked and the surface coating now containing theMaillard reaction product is substantially adsorbed into the outerinterstices of the proteinaceous food article.

The proteinaceous food article rests at point 39 in box 40.

In view of the fact that the proteinaceous food article prior to cookingcontains more than 50% water, the use of the solvents such as glycerineor mixtures of glycerine propylene glycol or mixtures of propyleneglycol and ethanol is not necessary (although such use of a solvent ispreferred). Thus, referring to FIG. 2B, FIG. 2B is a cut-away sideelevation view of a coated food article coated with encapsulatedMaillard reaction product reagents with the optional pH adjustmentagent. The proteinaceous food article is indicated by reference numeral12. The encapsulated sugar is indicated by reference numeral 16 with theactual sugar being indicated by reference numeral 30 and the fatencapsulating agent being indicated by reference numeral 28. Theencapsulated pH adjustment agent, sodium carbonate is indicated byreference numeral 18 with the actual sodium carbonate particle beingindicated by reference numeral 32 and the fat encapsulating agent beingindicated by reference numeral 26. The amino acid reactant is indicatedby reference numeral 20 with the actual amino acid particle beingindicated by reference numeral 34 and the fat encapsulating agent beingindicated by reference numeral 24. Again, the fat encapsulation iscarried out by using the processes of FIGS. 3, 4 and 5.

FIG. 2A is a cut-away side elevation view (in schematic form) of amicrowave oven 138 containing a coated food article prior to and duringthe carrying out of the process of our invention, wherein the coating isof the type set forth in detail in FIG. 2B.

A turkey or chicken drumstick having proteinaceous fibrous muscle tissue12 is coated with capsules 16, 18 and 20 as shown in FIG. 2B. Theuncooked proteinaceous muscle tissue drumstick is contained in microwaveoven 138, more specifically in box 40 wherein microwave source 42 emitsenergy substantially perpendicular to the upper surface of the foodarticle. The microwave energy passes through the surface of the muscletissue and causes the reaction to take place (aided by the evolution ofwater vapor from the muscle meat tissue 12) whereby Maillard reactionproducts are produced. The water in the meat muscle tissue 12 heats upand activates the molecules of the reactants in capsules 16, 18 and 20.Simultaneously, the solid material 12 (the meat muscle tissue) is heatedand the Maillard reaction products are adsorbed through the surfacethereof into the outer interstices of the meat muscle tissue product 12.Prior to 900 seconds (preferably 600 seconds) the entire drumstick iscooked and the surface coating now containing the Maillard reactionproduct is substantially adsorbed into the outer interstices of thedrumstick. The food article rests at point 39 in box 40.

FIG. 3 sets forth a schematic block flow diagram of the process forproducing spray chilled Maillard reaction reagent containing powder ordrum chilled Maillard reaction reagent containing powder useful informing material for incorportation into the interstices of the uncookedproteinaceous muscle tissue food product during cooking.

Individual Maillard reaction reagent taken optionally with pH adjustmentmaterial (e.g. sodium carbonate or sodium bicarbonate, for example) inlocation 501 is admixed with molten fat from location 505 (optionallyadmixed with fat emulsifier from location 503) with the mixing takingplace in mixing means 507 together, optionally, with texturizer fromlocation 509.

The resultant mixture created at mixing means 507 may then either bespray chilled at location 511 or drum chilled at location 513. The spraychilled precursor product at location 515 is then admixed withadditional spray chilled precursor product (for example, spray chilledencapsulated amino acid is admixed with spray chilled encapsulatedsugar) which may be further admixed with spray chilled sodium carbonate.

The drum chilled product from location 513 is ground at location 517yielding individual drum chilled precursor powder. The drum chilledprecursor, for example, drum chilled encapsulated amino acid may then beadmixed with drum chilled or spray chilled encapsulated sugar which maybe further admixed with drum chilled or spray chilled pH adjustmentagent such as encapsulated sodium carbonate or encapsulated sodiumbicarbonate.

Samples of fatty materials useful in this process are set forth supraand their respective melting points are as follows:

                  TABLE I                                                         ______________________________________                                        Fatty Material       Melting Point Range                                      ______________________________________                                        Partially hydrogentated                                                                            141-147° F.                                       cotton seed oil                                                               Partially hydrogenated                                                                             152-158° F.                                       soybean oil                                                                   Partially hydrogenated                                                                             136-144° F.                                       palm oil                                                                      Mono and diglycerides                                                                              136-156° F.                                       Glycerol monostearate                                                                              158° F.                                           Glycerol monopalmitate                                                                             132° F.                                           Propylene glycol monostearate                                                                      136° F.                                           Polyglycerol stearate                                                                              127-135° F.                                       Polyoxyethylene sorbitol beeswax                                                                   145-154° F.                                       derivatives                                                                   Polyoxyethylene sorbitan                                                                           140-144° F.                                       esters of fatty acids                                                         Sorbitan monostearate                                                                              121-127° F.                                       Polyglycerol esters of                                                                             135-138° F.                                       fatty acids                                                                   Beeswax              143-150° F.                                       Carnauba wax         180-186° F.                                       ______________________________________                                    

Texturizers include precipitated silicon dioxide, for example, SIPERNAT®50S (bulked density 6.2 pounds per cubic foot; particle size 8 microns;surface area 450 square meters per gram manufactured by the DegussaCorporation of Teterboro, N.J. Other silicon dioxide texturizers are asfollows:

SIPERNAT® 22S manufactured by Degussa Corporation;

ZEOTHIX® 265 manufactured by J. M. Huber Corporation of Havre de Grace,Md.;

CAB-O-SIL® EH-5 manufactured by the Cabot Corporation, of Tuscola, Ill.;

FIG. 4 is a diagram of the process and apparatus (in schematic form) forproducing spray chilled Maillard reaction precursor powder useful in theprocess of our invention (which powder may additionally contain Maillardreaction promoter and pH adjustment agent). Maillard reaction precursormaterials, fat emulsifier in molten state and texturizer are admixed inmixing kettle 601. The resulting mixture is spray chilled in spraychiller 603 and the resulting spray chilled particles containingMaillard reaction precursor and optionally pH adjustment agent andoptionally Maillard reaction promoter are classified. The classificationis carried out in cyclone separator 605 with the larger size particleswhich are useful in the practice of our invention going through seive607 into receiver 609.

More specifically, the molten mixture maintained in the fluid state ispumped to the "spray chiller" which is actually a spray dryer andatomized into fine droplets using an atomizer. A nozzle may bespecifically engineered to exclude chilled air or chilled air may beutilized to solidify the resulting fat particles. Atmospheric unheatedair may be used to blow through the spray dryer. The final productcollected is in fine powder form with particles about 50-120 microns insize.

FIG. 5 is a schematic diagram setting forth a process and apparatususeful in preparing drum chilled Maillard reaction reagent powder(additionally containing Maillard reaction promoter and Maillardreaction pH adjustment agent) useful in carrying out the process of ourinvention, wherein the resulting powder separately contains amino acid,sugar and pH adjustment agent. Each of these materials is produced in aseparate step.

The Maillard reaction reagent precursor material, for example, the aminoacid arginine is admixed with molten fat and emulsifier (optional) andtexturizer (optional) in mixing kettle 701. The molten material is thenpumped through feed line 703 into drum chiller 709. The resulting drumchilled product collected at location 705 is passed into grinder/sifter711 and then collected at location 713.

An example of a grinder/sifter useable in the instant invention is theKEMUTEC BETAGRIND®. Another example of workable apparatus is theKEK-Gardner Centrifugal Sifter.

FIG. 6 sets forth a schematic block flow diagram of the process of ourinvention whereby fluid, e.g., glycerine located at 302 and encapsulatedMaillard reaction reagents from location 301 are mixed at second mixingmeans 304. The resulting slurry is utilized at coating means 306.Proteinaceous muscle tissue meat product, e.g., chicken breast meat fromlocation 306, is coated at coating means 306 and then placed intomicrowave heating means 138 wherein the proteinaceous food product iscooked for a period of time less than 900 seconds (preferably less than600 seconds) and transported for marketing to location 310. Theprecursor particle materials individually produced according to theprocesses shown in FIGS. 3, 4 and 5 supra are shown as individualparticles coming from locations 301A, 301B and 301C. Thus, for example,encapsulated amino acid particles produced according to the process ofFIG. 5 are located at location 301A. Encapsulated sugar particlesproduced according to the process of FIG. 4 are located at location301B. Encapsulated pH adjustment agents such as fat encapsulated sodiumcarbonate or fat encapsulated sodium bicarbonate at location 301C areproduced according to the process of FIG. 4.

FIG. 7 sets forth the schematic block flow diagram of another aspect ofthe process of our invention whereby Maillard reaction reagent precursorpowder, for example, drum chilled fat encapsulated amino acid fromlocation 401A (produced according to the process of FIG. 5), spraychilled fat encapsulated sugar from location 401B (produced according tothe process of FIG. 4) and drum chilled fat encapsulated pH adjustmentagent sodium carbonate or sodium bicarbonate from location 401C(produced according to the process of FIG. 5) are admixed in flavorprecursor particle mixing means 401. The resulting mixture is thencoated onto meat muscle tissue (turkey breast, for example) fromlocation 403 at coating means 405. The coated meat muscle tissue fromlocation 405 is placed into microwave heating means 138 where microwavecooking takes place and the foodstuff to be cooked is completely cookedand edibly browned in a period of time under 900 seconds (preferablyunder 600 seconds). The resulting cooked articles are then transportedfor marketing to location 410.

It should be noted that an additional advantage achieved in practicingour invention wherein the flavor precursor liquid composition is coatedunto uncooked proteinaceous muscle tissue foodstuffs is that waterevaporation is retarded when the resulting coated product is cooked in amicrowave oven. This advantage, too, is unexpected, and unobvious andadvantageous.

The principies given above are illustrated in the following examples:

EXAMPLE I Formation of Spray Chilled Fat Encapsulated Xylose

Twelve hundred grams of xylose is admixed with 540 grams of 30% MYVERO®1806 and 1260 grams of DURKEE07 ® fat.

The spray chilling operation is carried out in accordance with theapparatus described for FIG. 4. The mixing is carried out in mixingkettle 601. The run time is 15 minutes. The yield is 1080 grams. Thefeed pump flow rate is 6.5 grams per minute.

Similarly fat encapsulated lysine and fat encapsulated sodium carbonateare produced.

The yield of the fat encapsulated lysine is 1730 grams.

The yield of the fat encapsulated sodium carbonate is 670 grams.

The feed temperature is between 80° and 90° C.

EXAMPLE II Production of Chicken Browning Mix

The objective of this experiment is to make a good browning mixturewhich works on a chicken breast filet cooked in a microwave oven.

Chicken breast filets were cut into 6×12×0.7 cm pieces.

0.4 Grams of a browning mix powder containing 2 grams encapsulatedxylose, 2 grams encapsulated lysine and 2 grams encapsulated sodiumcarbonate was added onto each piece of chicken breast.

The chicken breasts were placed into a 700 watt microwave oven and thechicken pieces were cooked at medium power for 2 minutes.

Aesthetically pleasing, edibly browned chicken filets were produced.

Substantially, identical results were created using the followingchicken browning coating mixtures:

    ______________________________________                                        Ingredients       Parts by Weight                                             ______________________________________                                        EXAMPLE II-2:                                                                 Xylose            2 grams                                                     Lysine            2 grams                                                     Sodium Carbonate  2 grams                                                     METHOCEL ® A15-LV                                                                           2 grams                                                     METHOCELLUSE)                                                                 EXAMPLE II-3:                                                                 Ribose            2 grams                                                     Lysine            2 grams                                                     Sodium Carbonate  2 grams                                                     EXAMPLE II-4:                                                                 Glucose           2 grams                                                     Lysine            2 grams                                                     Sodium Carbonate  2 grams                                                     EXAMPLE II-5:                                                                 Lactose           2 grams                                                     Lysine            2 grams                                                     Sodium Carbonate  2 grams                                                     EXAMPLE II-6:                                                                 Fructose          2 grams                                                     Lysine            2 grams                                                     Sodium Carbonate  2 grams                                                     EXAMPLE II-7:                                                                 Glucose           2 grams                                                     Cysteine          2 grams                                                     Sodium Carbonate  2 grams                                                     EXAMPLE II-8:                                                                 Xylose            2 grams                                                     Cysteine          2 grams                                                     Sodium Carbonate  2 grams                                                     EXAMPLE II-9:                                                                 Fructose          2 grams                                                     Cysteine          2 grams                                                     Sodium Carbonate  2 grams                                                     EXAMPLE II-10:                                                                Glucose           2 grams                                                     Methionine        2 grams                                                     Sodium Carbonate  2 grams                                                     EXAMPLE II-11:                                                                Xylose            2 grams                                                     Methionine        2 grams                                                     Sodium Carbonate  2 grams                                                     EXAMPLE II-12:                                                                Fructose          2 grams                                                     Methionine        2 grams                                                     Sodium Carbonate  2 grams                                                     ______________________________________                                    

EXAMPLE III Chicken Browning Mix

An example similar to Example II is carried out except the chickenbreast filet size was larger (10×6×0.7 cm). The cooking time was 2minutes at medium power using a CAROUSEL II SHARP® 700 watt microwaveoven. Each browning was prepared by grinding in a mortar and sprinklingon the surface of the chicken piece.

The coating mixes produced according to the procedure of Example I wereas follows and the degree of browning was as follows:

    ______________________________________                                                                     DEGREE OF                                                                     BROWNING                                                                      (SCALED                                          SAMPLE             AMOUNT    FROM                                             COMPOSITION        ADDED     1 to 5)                                          ______________________________________                                        EXAMPLE III-1                                                                 2 g  lysine            0.4 g     +5                                           2 g  lysine                                                                   2 g  xylose                                                                   2 g  Na.sub.2 CO.sub.3                                                        EXAMPLE III-2                                                                 2 g  lysine            0.4 g     +2                                           2 g  xylose                                                                   1 g  lysine                                                                   EXAMPLE III-3                                                                 2 g  lysine            0.4 g     +1                                           2 g  xylose                                                                   0.5 g                                                                              citric acid                                                              EXAMPLE III-4                                                                 2 g  lysine            0.4 g     +1                                           2 g  Ascorbic acid                                                            2 g  Na.sub.2 CO.sub.3                                                        EXAMPLE III-5                                                                 2 g  lysine            0.4 g     +2                                           1 g  Ascorbic acid                                                            2 g  Na.sub.2 CO.sub.3                                                        EXAMPLE III-6                                                                 2 g  lysine            0.4 g     +1                                           2 g  Ascorbic acid                                                            1 g  Na.sub.2 CO.sub.3                                                        EXAMPLE III-7                                                                 2 g  lysine            0.4 g     +1                                           2 g  Ascorbic acid                                                            0.5 g                                                                              citric acid                                                              EXAMPLE III-8                                                                 2 g  lysine            0.4 g     +1                                           2 g  Ascorbic acid                                                            2 g  Na.sub.2 CO.sub.3                                                        EXAMPLE III-9                                                                  2 g YMB-29(Yeast Extract)                                                                           0.4 g     +5                                           2 g  xylose                                                                   2 g  Na.sub.2 CO.sub.3                                                        EXAMPLE III-10                                                                2 g  VEGAMINE ® 128                                                                              0.4 g     +4                                           2 g  xylose                                                                   2 g  Na.sub.2 CO.sub.3                                                        EXAMPLE III-11                                                                2 g  Hydrolyzed Vegetable                                                                            0.4 g     +3                                                Protein                                                                  2 g  xylose                                                                   2 g  Na.sub.2 CO.sub.3                                                        EXAMPLE III-12                                                                2 g  Thiamine Na       0.4 g     +2                                           2 g  xylose                                                                   2 g  Na.sub.2 CO.sub.3                                                        EXAMPLE III-13                                                                2 g  VEGAMINE ® 128                                                                              0.6 g     +5                                           2 g  Fructose                                                                 2 g  Na.sub.2 CO.sub.3                                                        EXAMPLE III-14                                                                2 g  lysine            0.45 g    +5                                           2 g  xylose                                                                   2 g  Na.sub.2 CO.sub.3                                                        1 g  KOLLIDON ® 25 (BASF)                                                      Registered trademark for                                                      (Polyvinyl Pyrrolidone)                                                       manufactured by BASF)                                                    EXAMPLE III-15                                                                2 g  lysine            0.45 g    +5                                           2 g  Fructose                                                                 2 g  Na.sub.2 CO.sub.3                                                        1 g  KOLLIDON ® 25 (PVP)                                                  ______________________________________                                    

The polyvinyl pyrrolidone as shown in Examples III-14 and III-15increase the browning intensity of the browning mixes.

    ______________________________________                                                                   DEGREE OF                                                                     BROWNING                                                            AMOUNT    (SCALED FROM                                       SAMPLE COMPOSITION                                                                             ADDED     1 to 5)                                            ______________________________________                                        EXAMPLE III-16                                                                2 g  lysine          0.4 g     +2.5                                           3 g  glucose                                                                  3 g  Na.sub.2 CO.sub.3                                                        EXAMPLE III-17                                                                2 g  VEGAMINE ® 128                                                                            0.4 g       +1                                           2 g  glucose                                                                  3 g  Na.sub.2 CO.sub.3                                                        EXAMPLE III-18                                                                2 g  VEGAMINE ® 128                                                                            0.4 g       +1                                           3 g  Fructose                                                                 3 g  Na.sub.2 CO.sub.3                                                        EXAMPLE III-19                                                                2 g  VEGAMINE ® 128                                                                            0.4 g       +1                                           3 g  Fructose                                                                 3 g  Na.sub.2 CO.sub.3                                                        0.5 g                                                                              CENTROLEX ® 5                                                             (Lecithin)                                                               ______________________________________                                    

What is claimed is:
 1. A particulate flowable flavoring powder isprepared according to a process comprising the steps of:(i) providingthe separate Maillard reaction components:an amino acid; a sugar and,optionally, a pH adjustment agent; (ii) heating a high melting pointnormally solid encapsulating material to melt the encapsulating materialforming a molten encapsulating agent; (iii) separately mixing each ofsaid separate Maillard reaction components with discrete individualportions of said molten encapsulating agent thereby forming separateencapsulated Maillard reaction reagent-containing compositions; (iv)spray chilling or drum chilling each of the encapsulated Maillardreaction reagent-containing compositions to provide discrete particlesof solid Maillard reaction reagent-containing agent; and (v) mixing theresulting products thereby causing formation of said particulateflowable flavoring powder.
 2. The product of claim 1 wherein theencapsulating material has a melting point of from 130° F. to 195° F. 3.The product of claim 1 wherein the encapsulating material is a fat orwax having a melting point in the range of from 130° F. to 195° F. 4.The product of claim 1 wherein the encapsulating material is at leastone hydrogenated or partially hydrogenated vegetable oil, stearin, fattyglyceride ester or partial ester or an edible wax.
 5. The product ofclaim 4 wherein the encapsulating agent is a partially hydrogenatedcottonseed oil, a partially hydrogenated soybean oil, a partiallyhydrogenated palm oil, a glyceryl monostearate, a glycerylmonopalmitate, a propylene glycol monostearate, a polyglycerol stearate,a polyoxyethylene sorbitol, a fatty acid ester of polyoxyethylenesorbitan, a polyglycerol ester of a fatty acid, beeswax or carnauba wax,paraffin wax or candellila wax.
 6. A particulate flowable flavoringpowder which is prepared according to a process comprising:(i) providingthe separate Maillard reaction components:an amino acid; a sugar and,optionally, a pH adjustment agent; (ii) heating a high melting pointnormally solid encapsulating material and at least one emulsifier tomelt the encapsulating material and emulsifier; (iii) admixing themelted encapsulating material and emulsifier; (iv) separately mixingeach of the Maillard reaction components with a texture conditioningagent to form Maillard reaction component-texture conditioning agentmixtures; (v) separately mixing each of the Maillard reactioncomponent-texture conditioning agent mixtures with discrete individualportions of the molten mixture of encapsulating agent and emulsifier toobtain homogeneous mixtures in the form of emulsions; (vi) mixing theresulting emulsions; (vii) chilling the resulting emulsions to providediscrete particles of solid encapsulated Maillard reactionreagent-containing composition; and (viii) mixing the resulting productthereby causing the formation of said particulate flowable flavoringpowder.
 7. A product according to claim 6 wherein the textureconditioning agent is a silicon dioxide, powdered cellulose, puffeddextrin, maltodextrin or pregelatinized starch.
 8. A product accordingto claim 6 wherein the emulsifier is at least one mono- or diglycerideof a fatty acid.
 9. A product according to claim 6 wherein theencapsulating material has a melting point of from 130° F. to 195° F.10. A product according to claim 6 wherein the encapsulating material isa fat or wax having a melting point in the range of from 130° F. to 195°F.
 11. A product according to claim 6 wherein the homogeneous mixture ischilled by spraying the mixture into a stream of gas, the gas having atemperature of from 40° F. to 116° F.
 12. A product according to claim11 wherein the spraying is carried out with a centrifugal atomizer. 13.A product according to claim 11 wherein the homogeneous mixture isadmixed with compressed air and sprayed through a nozzle.
 14. A productaccording to claim 11 wherein the chilling step (iv) is carried out bycontact with a surface at a temperature less than the melting point ofthe encapsulating material to form flakes.
 15. A product according toclaim 14 wherein the flakes are reduced in size to pass through a No. 10screen.
 16. A process for preparing particulate flowable flavoringpowder comprising the steps of:(i) providing the separate Maillardreaction components:an amino acid; a sugar, and optionally, a pHadjustment agent; (ii) heating a high melting point normally solidencapsulating material to melt the encapsulating material forming amolten encapsulating agent; (iii) separately mixing each of saidMaillard reaction components with discrete individual portions of saidmolten encapsulating agent thereby forming separate encapsulatedMaillard reaction reagent-containing compositions; (iv) drying each ofthe encapsulated Maillard reaction reagent-containing compositions toprovide discrete particles of solid Maillard reaction reagent-containingagents; and (v) mixing the resulting products thereby causing theformation of said particulate flowable flavoring powder.